Rubber footwear with neoprene layer

ABSTRACT

A waterproof footwear includes a neoprene sock having a floor region and a side wall extending upward therefrom terminating in an upper edge. An outer rubber layer is bonded to and covers the entire outer surface of the neoprene sock side wall. A rubber floor portion covers the floor region of the neoprene sock and an outsole is attached to the rubber layer.

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to the field of footwearand more particularly to a waterproof rubber footwear. Waterprooffootwear such as boots are used in outdoor recreational activities aswell as in a number of industrial and professional uses. Specificallywaterproof boots are used in hunting and fishing to ensure that thesportsman feet remain dry during the recreational activity.Additionally, waterproof boots are used in the animal husbandry andfarming environments as well as by firefighters.

[0002] One type of waterproof boot includes an outer rubber waterprooflayer. The use of rubber as the waterproof material provides a number offunctional benefits. One such benefit is that rubber of sufficientthickness is strong and resilient, resistant to punctures, durable, andin the area of outdoor recreational sports is scent proof. However,rubber boots are typically inflexible, heavy, and do not fully fit thefoot and/or leg of the user very well.

[0003] There have been a number of attempts to provide a waterproof bootto minimize the negative aspects of rubber. One such attempt has beenmade by the Muck Boot Company which has replaced the outer rubbermaterial with a neoprene material covered with an outer layer of fabric.While the neoprene covered fabric provides a waterproof boot, theneoprene is not as durable or puncture proof as rubber. Additionally,the nylon coated neoprene absorbs and gives off scent which isundesirable for the outdoor sportsman.

[0004] Another attempt to use a neoprene inner sock is disclosed in U.S.Pat. No. 5,937,543 entitled “Footwear having a Variable Sized Interior”by the U.S. Navy. The '543 patent discloses a neoprene inner sock thatis smaller than and partially attached to the outer rubber covering sothat users with different feet size may be able to use the same boot.However, U.S. Pat. No. 6,427,362 entitled “Boot with Strapping toRestrain Movement of Foot” assigned to Norcross Safety Products, L.L.C.,argues that the boot disclosed in the '543 patent “cannot be easilymanufactured with a predominantly rubber upper and with a predominantlyrubber sole, by conventional vulcanizing methods, as closed cellneoprene foam takes a set and loses its elasticity when vulcanized” [SeeCol. 1 lines 35-46].

[0005] Accordingly, it would be desirable to provide a rubber boot thatis durable, puncture resistant, light weight, flexible, and scent proof,and fits and conforms to the foot in a comfortable way. It would furtherbe desirable to combine the thermal protection of neoprene with thewaterproof layer of rubber in order to provide thermal protection thatstill allows the boot to be lightweight and flexible.

SUMMARY OF THE INVENTION

[0006] One feature of the invention is to provide a waterproof boot thatis lightweight and flexible. Another feature of the invention is toprovide a lightweight waterproof boot with thermal protection. A furtherfeature of the invention is to provide a rubber coated waterproof boothaving a neoprene layer that is scent proof.

[0007] In one embodiment, a shoe includes a neoprene sock having a floorregion and a side wall extending upward therefrom terminating in anupper edge. An outer rubber layer is bonded to and covers the entireouter surface of the neoprene sock side wall. A rubber floor portioncovers the floor region of the neoprene sock and an outsole is attachedto the rubber layer.

[0008] In another embodiment a waterproof boot includes an upperincluding an outer layer of rubber and an inner layer of neoprene. Therubber covered neoprene extends to a top edge of the upper. A floorincludes a neoprene portion attached to the neoprene layer of the upper,and a rubber portion bonded to the neoprene portion and the rubber layerof the upper. An outsole is attached to the upper forming a waterproofbarrier.

[0009] In still another embodiment, a method for manufacturing awaterproof shoe includes first forming a sock from a neoprene materialhaving an inner surface and an outer surface; a floor region configuredto contact the bottom portion of a user's foot, and an upper regionextending from the floor region and terminating at an upper edge. Theneoprene sock is then placed over a last such that the outer surface isexposed. A rubber layer of material is placed over the entire upperregion of the outer surface of the neoprene sock. The rubber coveredneoprene sock is then vulcanized.

[0010] In yet another embodiment, a footwear includes an upper includinga neoprene layer having an inner surface, an outer surface, a loweredge, and an upper edge. An outer rubber layer is bonded to and coveringsubstantially the entire outer surface of the neoprene layer. An outsoleis attached to the outer rubber layer. The outer rubber layer may alsobe bonded to and completely cover the entire outer surface of theneoprene layer.

[0011] In a further embodiment, a waterproof footwear includes an upperincluding an outer layer of rubber and an inner layer of neoprene. Therubber covered neoprene extends to a top edge of the upper. A floorincludes a neoprene portion attached to the neoprene layer of the upper.A rubber portion is bonded to the neoprene portion and the rubber layerof the upper. A rubber outsole is attached to the upper forming awaterproof barrier.

[0012] In still another embodiment a method for making footwear includescovering an upper region of a last with a layer of neoprene having anouter surface. The layer of neoprene is then substantially covered witha layer of rubber. The rubber layer and neoprene layer is thenvulcanized.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013]FIG. 1 is a cross sectional view of one embodiment of thewaterproof footwear.

[0014]FIG. 2 is a metal last used in the manufacture of the waterprooffootwear boot.

[0015]FIG. 3 is a sock sewn out of neoprene material.

[0016]FIG. 4 is a neoprene sock stretched over the last of FIG. 2.

[0017]FIG. 5 is a schematic of the rubber sheets with cement appliedthereto.

[0018]FIG. 6 is a the rubber sheets adhesively attached to the neoprenesock.

[0019]FIG. 7 is the outsole to be adhered directly to the rubber coveredneoprene.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Referring to FIG. 1, a boot 10 includes an upper 12, an outsole14, a midsole 16, and an insole 18. Upper 12 includes an outer rubberlayer 20 extending around an inner neoprene sock 22 having an outerneoprene layer 24 and a inner fleece layer 26. The inner layer 26 couldbe other materials known in the art including but not limited toTHINSULATE, cotton, nylon, cotton, canvas, mesh or wool. The term fleeceis used herein to represent any of these materials. The neoprene layer24 extends to a top edge 28 of the upper 12.

[0021] Neoprene sock 22 is formed from at least two pieces of neoprenematerial. One piece of neoprene material defines a floor region 30 uponwhich a users foot rests and a second upper region 32 surrounding thesides and top of a user's foot including the ankle and calf region. Thefloor region 30 of the neoprene layer may be connected to the upperregion 32 of neoprene by a threaded stitch 34.

[0022] The neoprene sock 22 forms the foundation upon which the entireboot 10 is constructed. Referring to FIGS. 2-7, the neoprene sock 22 isplaced upon a metal last 36 that defines the interior region of boot 10.The neoprene sock 22 is stretched over the metal last 36 with the fleecelayer 26 adjacent last 36 and with the neoprene layer 24 of sock 22facing outward. A plurality of individual rubber sheets or pieces 38 arecut to cover the exposed layer of neoprene. A bonding cement is appliedto one or both of the rubber sheets and neoprene sock in order totemporarily secure the rubber pieces 38 to neoprene layer 26. The rubbersheets 38 cover both upper portion 32 of the neoprene sock 22 as well asthe floor portion 30 of neoprene sock 22. In this manner rubber sheets38 completely cover the neoprene sock 22.

[0023] In the next step of the operation, a sole 40 including a rubberoutsole 14 and a midsole 16 is adhesively applied directly to the rubbersheet 38 covering the floor portion 30 of neoprene sock 22. The sole 40further includes an upwardly extending portion 42 that covers a loweredge 44 of the rubber layer 20 material. Finally the entire assembly isplaced into an autoclave and subject to heat and pressure to vulcanizethe rubber sheets 38 such that the rubber material bonds directly to theneoprene layer 24 and to outsole 40.

[0024] In another embodiment an insole 18 is located between the floorportion 30 of neoprene sock 22 and rubber material 38 that covers thefloor portion 30. Insole 18 is adhesively attached to the floor portion30 to provide a smooth planar surface upon which the rubber materialportion 38 is applied to the rubber material 38 forming the upper.Insole 18 may be formed from one or more pieces of material as iscommonly known in the art. The sole 40 is then applied as discussedabove prior to being vulcanized.

[0025] In another embodiment, midsole 16 is formed of an EVA (ethylvinyl acetate) material providing a lighter weight material than arubber midsole. Sole 40 with an EVA midsole may be attached to therubber upper prior to or after vulcanization. However, midsole 16 mayalso be formed from other materials such as polyurethane, rubber, phylonor other materials known in the art.

[0026] The neoprene layer 24 and outer rubber sheets 38 once vulcanizedprovide a flexible composite which is less rigid than previously rubberboots since the neoprene material provides and allows for the outerrubber sheets 38 to retain a certain degree of resiliency. The rubbermaterial 38 is bonded directly to the neoprene material 22 around theentire region upon which the rubber is in contact with the outer surfaceof a neoprene layer. As illustrated in FIG. 1 the rubber layer 20encompasses the entire outer periphery of the neoprene sock 22 coveringthe bottom of floor portion 30 of a neoprene sock 22 to the top 28 edgeof the upper 12 of boot 10.

[0027] In an alternative embodiment, the outer rubber material forms anouter bond upon which an insole 18 is sandwiched between the floorportion 30 and the lower rubber material 38. However, the entire regionfrom the heel and toe upward to the top edge 28 of boot 10 the rubber isattached to the neoprene liner or sock 22 prior to vulcanization. Thiscontinuous bonding allows for the rubber and neoprene material toprovide a flexible and resilient feel for the user while also allowingfor a durable puncture proof outer surface and further retaining thescent proof characteristic that is desirable for this product.

[0028] In one preferred embodiment, the rubber layer 20 covering theneoprene layer 24 is about 0.030 inches. The neoprene sock 22 itself is4.5 millimeters thick with the neoprene layer 24 being about 3millimeters thick and the fleece layer 26 on the inside surface of theneoprene being 1.5 millimeters. Accordingly, the total thickness of theouter rubber layer 20, neoprene layer 24 and fleece 26 layer isapproximately 0.250 inches. Of course the layers may be of otherthickness as well.

[0029] In a preferred embodiment, the neoprene layer 24 is a closed cellfoam rubber which may be SBR or CR type. However, other types ofneoprene may also be used and still fall within the scope of theinvention. It should also be noted that the thickness of the neoprenelayer 24 may be less than or greater than 0.030 inches. The rubber boot10 as disclosed in the embodiment shown in FIG. 2 includes a midsole 16formed of a EVA material that is substantially lighter than a similarrubber boot that does not use a neoprene layer and having a midsoleformed of rubber. In fact, this type of boot disclosed is 30% lighterthan similar boots with an all rubber sole and a separate THINSULATElayer that is currently used in the prior art.

[0030] This resulting construction includes both a reduction in weightby the utilization of neoprene and by changing the way the outsole isattached to provide for a midsole made of EVA material. Additionally,there is an improved fit to the user because a neoprene rubbercombination stretches and forms to a users foot. The boot may be smallerin size and volume for a particular user since it will be more snug tothe foot and its greater resiliency allows for a more comfortable wearand a smaller size. The increased resiliency of the rubber coatedneoprene allows a user to roll over the shaft area 46 of upper 12.Additionally, the resilient nature of the rubber coated neoprene allowsthe shaft area 46 to be repeatedly rolled or folded over without out thedanger of cracking or failure of the rubber layer.

[0031] The sloppy fit or loose fit that has been accompanied with largerubber boots is thereby eliminated. The large fit was required due tothe inflexibility and hardness of the outer rubber material whichresults when the outer rubber material is bonded to the standard nylonmaterial as used in the art. Since neoprene material provides insulativeproperties, the amount of fleece that would otherwise be required in theboot is reduced thereby adding to the reduction both in bulk and weightof the overall product. As illustrated in FIG. 1, the neoprene layer 24extends from the top edge 28 of upper 12 through the vamp area 48 aroundthe toe region across the floor of the boot, and around the heel andankle region of the boot. In one embodiment, the neoprene layer issecured to a rubber layer completely around the entire outer peripheryof the neoprene layer. In an alternative embodiment, the outer rubberlayer is bonded to the neoprene layer 24 in all regions except where aninsole 18 is placed between the floor portion 30 and the rubber floorcovering 50. In both of these embodiments, a complete waterproof rubberlayer is formed about the neoprene sock 22 independent of the sole 40.Of course it is contemplated that the rubber floor portion 50 may beomitted if desired. However, any leaking that may occur between the sole40 and upper 12 may result in water seeping into the inner area of theboot through stitches 34, or any other seam that may be created toattach the neoprene floor portion 30 with the upper portion of theneoprene sock 22.

[0032] In one embodiment, the upper edge of the neoprene layer in theupper of the footwear is at least 4 inches from the bottom of the sole.In another embodiment, the upper edge of the neoprene layer is at leastsix inches from the bottom of the sole. In certain applications such asboots, the upper edge of the neoprene layer may be at least 18 inchesfrom the bottom of the sole. Additionally, in footwear used as hip orchest waders, the upper edge of the neoprene layer may be up to 60inches or higher from the bottom of the sole. The neoprene materialplaced on the last in the method of manufacture may include a floorportion or only an upper portion. It may also be possible to constructthe neoprene material while on the last, however in a preferredembodiment the neoprene material is formed into a sock having at leastan upper tube portion and in another embodiment the sock includes afloor portion. In one embodiment, the upper edge of the neoprenematerial extends to the upper edge of the footwear and is completelycovered with the outer rubber layer. In another embodiment, the upperedge of the neoprene material may be lower than the upper-edge of theouter rubber material. It is also possible that a flexible rubbersection such as a folded pleat be built into a portion of the footwearproximate the upper edge of the footwear and extending only a portion ofthe upper periphery of the footwear. Similarly, an expansion portionmaybe located proximate the upper edge of the footwear and include apiece of material that is flexible to allow for easier expansion andstretching than the neoprene and rubber bonded layers. The flexibleregion may include a section of rubber 60 that is not bonded to an innerlayer of neoprene.

[0033] It will be understood that the above description is exemplaryembodiments and that the invention is not limited to the specificembodiments described. Various substitutions, modifications, changes,and omissions may be made in the arrangement of the elements withoutdeparting from the scope of the invention as expressed in the appendedclaims.

What is claimed is:
 1. A footwear comprising: an upper including aneoprene layer having an inner surface, an outer surface, a lower edge,and an upper edge; an outer rubber layer bonded to and coveringsubstantially the entire outer surface of the neoprene layer; and anoutsole attached to the outer rubber layer.
 2. The footwear of claim 1,further including a neoprene floor portion including a neoprene portionattached to the neoprene layer.
 3. The footwear of claim 1, furtherincluding a rubber floor portion covering the neoprene floor portion andbonded to the outer rubber layer.
 4. The footwear of claim 1, whereinthe outer rubber layer includes an upper edge coterminous with the upperedge of the neoprene sock.
 5. The footwear of claim 1, further includinga layer of material attached to the inner surface of the neoprene layer.6. The footwear of claim 1, wherein the rubber floor portion is bondeddirectly to the neoprene floor portion.
 7. The footwear of claim 6,further including a midsole formed from ethyl vinyl acetate.
 8. Thefootwear of claim 6, further including an insole located between theneoprene floor portion and the rubber floor portion.
 9. The footwear ofclaim 5, wherein the neoprene floor region is stitched to the innerlayer of neoprene.
 10. The footwear of claim 1, wherein the outer rubberlayer does not hold a human scent.
 11. A waterproof footwear comprising:an upper including an outer layer of rubber and an inner layer ofneoprene, the rubber covered neoprene extending to a top edge of theupper; a floor including a neoprene portion attached to the neoprenelayer of the upper, and a rubber portion bonded to the neoprene portionand the rubber layer of the upper; a rubber outsole being attached tothe upper forming a waterproof barrier.
 12. The waterproof footwear ofclaim 11, including a layer of material secured to the neoprene layerdistal the rubber layer.
 13. The waterproof footwear of claim 12,wherein the layer of material is fleece.
 14. The waterproof footwear ofclaim 13, including a midsole located between the outsole and floor andbeing formed of ethyl vinyl acetate.
 15. The waterproof footwear ofclaim 14, further including an insole located between the floor portionand the midsole.
 16. A method of manufacturing a waterproof footwearcomprising: covering an upper region of a last with a layer of neoprenehaving an outer surface; covering substantially all of the layer ofneoprene with a layer of rubber; and vulcanizing the rubber layer andneoprene layer.
 17. The method of claim 16, further including covering abottom portion of the last with a layer of neoprene defining a floorregion.
 18. The method of claim 17, further including adhering a rubberlayer of material to the neoprene floor region.
 19. The method of claim17, including forming the neoprene sock by stitching a floor portion toat least one other neoprene piece of material.
 20. The method of claim18, further including securing a rubber outsole to the rubber coveredneoprene layer.
 21. The method of claim 20, further including securing amidsole formed from ethyl vinyl acetate to the outsole.
 22. The methodof claim 18, further including placing an insole between the floorportion of the neoprene material and floor portion and the rubber layerprior to the vulcanizing step.
 23. The method of claim 22, furtherincluding attaching a material to the inner surface of the neoprenelayer.
 24. The method of claim 23, wherein the material is fleece. 25.The method of claim 16, wherein the layer of neoprene is completelycovered by the layer of rubber.